High Performance Coal Fired. Achievement and R&D for Future

Transcription

1 Session Theme:Clean Coal saving the Earth and Economy High Performance Coal Fired Thermal Power Plant, Achievement and R&D for Future 8 th September, 2010 Toshiba Corporation Copyright 2007, Toshiba Corporation.

2 Contents 1. Introduction of Steam Turbine & Generator Achievements 2. Efficiency Improvement by Innovative Thermal Cycle 3. Development of Advanced-USC & CCS technologies 2

3 Contents 1. Introduction of Steam Turbine & Generator Achievements 2. Efficiency Improvement by Innovative Thermal Cycle 3. Development of Advanced-USC & CCS technologies 3

4 Turbine Power Plants supplied by Toshiba Bulgaria 3Units 532 MW Iran 4 Units 255 MW Kuwait 22 Units 4,470 MW Pakistan 3 Units 137 MW India 10 Units 2,458 MW Thailand 8 Units China 348 MW (incl. Taiwan Region) 49 Units 12,037 MW As of March 2010 Canada 10 Units 1,427 MW USA 96 Units 29,370 MW Iceland 1 Unit 34 MW UK 1Unit 210 MW Cyprus 2 Units 120 MW Egypt 6Units 1,764 MW Italy 4 Units 994 MW Nigeria 4 Units 56 MW Lebanon 4Units 130 MW Botswana 1 Unit 33 MW South Africa 2 Units 118 MW Bahrain 1 Unit 65 MW UAE 4Units 968 MW Sri Lanka 1 Unit 6MW Bangladesh 5 Units 41 MW Myanmar 2 Units 0.9 MW Malaysia 22 Units 4556 MW Philippines 27 Units 1,114 MW Japan 1,447 Units 81, MW Korea 28 Units 2,138 MW Nauru 1 Unit 0.1 MW Papua New Guinea 3 Units 135 MW Indonesia 15 Units 2,328 MW Australia 55 Units 11,672MW Puerto Rico Mexico 1 Unit 214 MW 30 Units Antigua 2,512 MW 2 Units 18 MW Costa Rica 1 Unit 55 MW Total: 1,890 Units, 160GW in 37countries since 1927 Venezuela 7Units 1,418 MW Brazil 3 Units 155 MW Argentina 3 Units 14 MW 4

5 Recent EPC Thermal Power Projects in the World Bulgaria Maritsa East 2 #1,3,4 3x177MW Coal Fired Plant Rehabilitation (COD:#1 Sep.2007, #3 Nov.2008, #4 Feb.2009) China - Taizhou #1,#2 2x1000MW Coal Fired USC 25MPa600/600 (COD:#1 Dec.2007/#2 Mar.2008) Japan Maizuru #2 900MW Coal Fired USC 24.5MPa595/595 (COD: Aug. 2010) USA - Iatan 2x1000MW Coal Fired USC 25.5MPa582/582 (Under Construction) Rumania Paroseni #4 1x150MW Coal Fired Plant Rehabilitation (COD: Aug.2007) India - Mundra 5x800MW Coal Fired USC 24.2MPa565/593 (Under Construction) Indonesia - Tanjung Jati B Extension 2x660MW Coal Fired (Under Construction) Malaysia - Tanjung Bin 3x700MW Coal Fired (COD:#1 Oct.2006/ #2 Feb./#3 Aug.2007) ( ) #2 Feb./#3 Aug.2007) Malaysia - Jimah 2x700MW Coal Fired (COD:#1 Jan./#2 Jul.2009) 5

6 Profile of the Project (1) KEPCO Maizuru #2 Power Plant (COD August, 2010) Customer: Kansai Electric Power Co., Japan Turbine: Cross Compound, Four Flow( CC4F ) Generator: Pri./Sec.:670MVA/370MVA Output: 900 MW Mi Main Steam: 25 MPag 595 Reheat Steam: 595 Rotation Speed: Pri./Sec.:3,600rpm/1,800rpm Features Top Level Plant Performance Various i Coals Available High-efficiency on Various Coals Sustainability and Landscape-Reserve, considering the Location adjacent to the quasi-national park Coal Fired Plant with the Latest Technologies 6

7 Profile of the Project (2) Eraring 660MW Thermal Power Station, Australia The record of continuous operation in the World (at 2003) Eraring Unit 4 & 10 (Australia): manufactured by Toshiba The continuous operation : 673 days (from Feb 26, 1995 to Dec31,1996) Availability : 99.63% The most reliable turbine & generator in the world 7

8 Profile of the Project (3) Anpara #4,#5 Power Station, India 8 years continuous commercial operation without major overhaul Customer: Uttar Pradesh State Electricity Board, India Taking over: Unit # 4: Feb 1994 Unit # 5: Oct 1994 Turbine: Tandem Compound, Double Flow, Reheat Type (TCDF-42 ) Output: 500 MW Main Steam: 166 barg, 538 Reheat Steam: 538 Rotation Speed: 3000 rpm Robust-Designed Turbine for Breakdown Maintenance 8

9 Contents 1. Introduction of Steam Turbine & Generator Achievements 2. Efficiency Improvement by Innovative Thermal Cycle 3. Development of Advanced-USC & CCS technologies 9

10 Growth of Thermal Power Plant ( ) Europe Shift to Low Emission Power Plants 42GW China Mega Market more than 50% in the World Local Manufactures Supplied Equipment 371GW 76GW Middle East Shift from Oil Fired to Natural Gas Fired 39GW Africa Coal Firing Unit & Combined Cycle Plant 80GW India Large Scale Coal Fired Thermal Plant 71GW 15GW Japan Construction of Combined Cycle Plant Asia & Oceania Large Scale Thermal Power Plant Geo Thermal 35GW America Shift from Coal to CC in North America Large Scale Thermal Plant in South America Source: IEA World Energy Outlook

11 Towards Clean Coal Thermal Power Plants 40 Gt Methods TOSHIBA activities Baseline Temperature Increase Performance Improvement (57%) High-efficiency i Equipment supply Rehabilitation 6 deg C of decrepit plants Advanced Countries Emerging Countries Advanced Countries 450ppm Stabilization Scenario temperature Increase deg C Renewable Energy (23%) Neucler(10%) CCS(10%) Hydro, CSP, Geothermal Thermal Plant with CCS Advanced Countries Emerging Countries Advanced Countries (Source: World Energy Outlook 2009) 26 Efficiency Improvement for CO2 Reduction 11

12 Coal-Fired Plant Efficiency in the World Gross Eff ficiency (LHV) 45 % 43 % The Latest Plant Efficiency Level 41 % Japan 39 % UK&Ireland 37 % German 35 % USA 33 % Australia 31 % China 29 % 27 % India 25 % Source: Ecofys International Comparison of Fossil Power Efficiency and CO2 Intensity 2009 Top Level Efficiency as Coal Fired Thermal Plant 12

13 CO2 Reduction by Efficiency Improvement World Total coal-fired thermal plant capacity: 1,440GW (1/3 of entire power plants capacity) Coal-Fired Thermal Plants Coal-Fired Thermal Plants in the World Others 37% India 5% USA 23% China 35% CO2 emissions * Effi iciency * (%) 40 1,440GW 35 Source: IEA World Energy Outlook 2009 ECOFYS, INTERNATIONAL COMPARISON OF FOSSIL POWER EFFICIENCY(2008) 30 Efficiency and CO2 emissions of The Latest Plant Efficiency Level Base 41.6% +760kt +1690kt +1760kt 36.7% 32.1% 31.8% Japan USA China India *Gross efficiency (LHV) *CO2 emissions from a 1,000MW plant Efficiency Improvement Technology Contributes to Reduction of CO2 emissions 13

14 Steam Cycles and Efficiency Gains Efficie ency Imp proveme ent (% re elative) / / / / / / MST/RST Temperature Main Steam Pressure (MPa) Higher the Pressure, Higher the Temperature More Gains on Efficiency and Subsequent CO 2 Reduction 14

15 Super Critical Turbine Experience Over 81 units of Toshiba s Super Critical STG have been operating since (except China) World Share of Supercritical Steam Turbine (Among Major Manufactures, Past 20 Years) Company E Company D 9% 14% TOSHIBA 27% 16% Company C Company B 16% 18% Company A as of 2009 Top Level efficiency Steam Turbines Supplied to the Markets 15

16 Transition of Steam Conditions MST/RST 600/610 KAWAGOE #1,#2 700MW (TC) (31MPag 566/566/566 ) NANAO OTA #2 700MW (TC) (24.1MPag 593/593 ) J-Power TACHIBANA BAY #1 1050MW (CC) (25MPag 600/610 ) TAIZOH #1&2 1000MW (TC) (25MPag 600/600 ) MAIZURU #2 900MW (CC) (24.5MPag 595/595 ) 593/593 HEKINAN #4,#5 IATAN 914MW (TC) NOSHIRO #2 1000MW (TC) (24.6MPag 582/582 ) 600MW (TC) (24.1MPag 566/593 ) (24.1MPag 566/593 ) 566/ / /566 TSURUGA #1 500MW (TC) (24.1MPag 566/566 ) HEKINAN #1 700MW (TC) (24.1MPag 538/566 ) HARAMACHI #1 1000MW (CC) (24.5MPag 566/593 ) TACHIBANA BAY 700MW (TC) (24.1MPag 566/593 ) CALLIDE #3,#4 420MW(TC) (25MPag 566/566 ) WESTON #4 5834MW (TC) (24.7MPag 582/582 ) TC : TANDEM COMPOUND CC : CROSS COMPOUND : 60Hz : 50Hz Towards to Top Level Steam Conditions 16

17 Steam Turbine Development based on CFD HP Steam Valve HP Turbine 1 st Stage Nozzle Cross-Over Piping Lead Piping Nozzle Box IP Exhaust LP Inlet IP Inlet Abradable Seal RH Steam Valve LP Exhaust Casing 17

18 Efficiency Improvement of Generator High-efficiency, large-capacity indirectly hydrogen-cooled turbine generator Reduce losses compared to water-cooled generators Award from The Japan Machinery Federation as Excellent Energy-saving Equipment in 2009 Generators: Primary 670MVA(600MW) Secondary 370MVA(300MW) Achieved the largest capacity and highest-efficiency in the world by indirectly hydrogen-cooled method 18

19 Steam Turbine Efficiency Improvement Steam Turbine Test Facility Mikawa Power Station Unit2 Turbine Test Facility (since June 2008) LP Turbine HP Turbine Generator MSV/CV Bypass valve Condenser Condenser Generator HP Turbine Speed: 6,000rpm Stages: 16 Boiler LP Turbine Speed: 3,600rpm Stages: 6 LSB: up to 50 in. Full-scaled Turbine Test Facility for R&D to Boost Up 19

20 Performance Improvement R&D Process New Technology R&D Planning 1 Blade loss reduction Rotational direction Optimized Reaction Stage Design Surface friction loss reduction Longitudinal flow distribution control nozzle 2 Pressure drop loss reduction Inlet/Exhaust scroll Steam valve piping connection part Section joint piping, duct 3 Leakage loss reduction Seal fin profile improvement Clearance reduction 4 Last stage blade development High efficiency LSB series Increased annulus area => Exhaust steam speed reduction => Loss reduction High mach number blades Smaller radical clearance Bucket Performance Improvement Cycle Verification Phase Analysis & Simulation Mikawa P/S Unit #2 Actual size test facility Practical Operation Utilization of the test results for Analysis & Simulation 20

21 Latest Development Steam Turbine Technology Optimal Reaction Blade Verified High Efficiency Direct Lubricated Bearings 35in LSB Drum-type Rotor Confirm 30% Loss Measure Moisture Confirm Rotor Dynamics Reduction Coefficient Abradable Coating Seal Confirm Low Leakage Loss and good Shaved Surface Welded Rotor Good Inspection Result after Long Operation Corrosion-Resistant Coating Confirm Coating Effect Various Technical Improvements for Both Performance & Reliability 21

22 Steam Turbine World Market Share Worldwide (Yr03-09 Except China, >100MW) 100% % US Market A Others B Others 日立 F 50% 三菱 D E D C TOSHIBA 8% 37% 36% 40% 32% 64% 46% 61% Alstom B Siemens C GE E Toshiba Total:362,393MW 0% No. 4 Share worldwide No.1 Share in US for 7 years 22

23 Advanced Technology for Plant Rehabilitation 450MW 169atg - 538/538degC TC4F-26 HIP Section Replace = Increased Heat Rate 0.8% 780MW 246atg - 538/538degC TC4F-30 LP Section Replace = Increased Power Output 18.6MW 1% efficiency improvement on 1,000MW rating coalfired plant means about 46,000t CO2 reduction per year. Latest Technology for High-efficiency & Life Extension 23

24 Profile of the latest Project (4) Bulgaria Maritsa East 2 #1-#6 6x177MW Plant Rehabilitation Customer Taking Over Maritsa East II TPP #1 Sep.2007, #2 Jan.2007 #3 Nov.2008, #4 Feb.2009 #5 (Mar.2011), #6 (Aug.2010) (under construction) (under construction) #1-4:4x150 MW STG Replacement Turbine:LMZ Make Toshiba Latest Turbine Generator:LMZ Make Toshiba Air Cooling Generator for unit2 40 Years old Machine to Latest #3,4: 2x210 MW LMZ Make Turbine Rehabilitation HP IP LP Blade Nozzle, LP Rotor Replacement 24 Years old Machine to renewal Rehabilitation of decrepit Units to Improve Efficiency 24

25 Contents 1. Introduction of Steam Turbine & Generator Achievements 2. Efficiency Improvement by Innovative Thermal Cycle 3. Development of Advanced-USC & CCS technologies 25

26 Turbine material for High Temperature Parts MW 24.1MPa MW 593/ MPa 566/ CrMoV alloy 12Cr alloy Further material development is underway to meet 700 condition Modified 12Cr Sub / Super Critical Advanced 12Cr 500MW 24.1MPa 566/566 A-USC New Material for A-USC USC (year) Material Development as National Project 26

27 A-USC (Advanced Ultra Super Critical) Turbines Boiler Overall system Steam condition Heat balance Main steam (35MPa 700C) Reheat steam VHP HP IP (750C) FWH Steam Valve High temperature material Steam turbine LP LP Condenser Generator Steam Turbine High temperature material Turbine Structure / Flowpath Re elative Impro ovement of Efficiency η η/η (%) /610C USC 700/720/720 A-USC Double Reheat 600/700C A-USC 566/566/566C USC Dual Reheat 538/566C USC Main Steam Pressure (MPa) Reheat Valves (φ400mm, 3.9ton) VHP Rotor TP (φ850mm, 7.7ton) VHP Cross Section Drive towards Advanced USC technology for future low CO2 emissions 27

28 CCS Pilot Plant Plant Overview - Location: Sigma Power Mikawa, Omuta, Fukuoka, Japan - Post Combustion Method - Capacity:2,100Nm 3 /hr (Feed) (10t-CO2/day) - Exhaust Flow: 2,100 Nm3/h - Commenced: September, 2009 Objectives - Testing using the actual flue gas of live thermal power plant - Verification of performance, operability, maintainability, etc. in view of scaled up plant design. Development in Progress for Full-Scaled Plant 28

29 Thermal Power Plant with CCS Steam Turbine Boiler Carbon Capture System Stack Generator Condenser DeNOx EP FGD Absorber Stripper Reboiler Compressor CO 2 Steam Extractions Exhaust CO O2 Discharge (t / MWh) Comparison of CO2 Discharge R&D for High Performance Solvent 29

30 1400 Towards Clean Coal Thermal Power Plant CO 2 Emis ssions (g grams / kwh) USC+CCS CCS ( 50% CO 2 Capture ) Sub Critical USC A-USC A-USC+CCS ( 50% CO 2 Capture ) 200 USC+CCS A-USC+CCS ( 90% CO 2 Capture ) ( 90% CO 2 Capture ) Plant Net Efficiency (LHV) Clean Coal Thermal Power Plant is realized by Integration and Optimization of both High efficiency Turbine Cycles and CCS technology 30

31 Toshiba Steam Turbine for Solar Power Plant Axial Flow Turbine (Below MW) Double Flow Turbine (Over MW) Four Flow Turbine (Over 400MW) Moisture Extraction Blade (MEB) MEB from Geothermal Technology Drain Catcher Drain Removal Grooves Steam turbine line-up for Renewable Energy Plant 31

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